Triple-lock main tee splice

Abstract

An improved connector for a main tee of a suspended ceiling grid that has multiple locking elements that increase connection tensile force properties. The connector has an end tab with a forward portion bent at a lead angle and a receiving pocket with an outwardly flared entrance that, with an opposed identical connector, cooperate to provide smooth horizontal alignment. The end portion, additionally, includes an edge profile that vertically aligns itself with the receiving pocket of the opposed connector. The receiving pocket includes a spring-like resilient wall that limits the assembly force to overcome interference with projecting lock elements. The spring-like pocket wall and shape of the lock elements contribute to an audible click signaling that a connection has been completed. One of the lock elements works with a relief groove to augment self-alignment of the connectors.

Description

BACKGROUND OF THE INVENTION[0001]The invention relates to improvements in suspended ceiling grid components and, in particular, to end connectors for main runners or tees of such systems.PRIOR ART[0002]It is difficult to produce a main tee grid splice connector with previously known designs that is consistently easy to assemble in the field and that will result in a reliable and positive interconnection. Various known end connectors for main runners or tees can be somewhat difficult to install for numerous reasons. Such connectors may not be self-aligning and if they have provisions for self-alignment, their performance in this regard may be marginal at best. Smooth engagement and coupling between end connectors can be obstructed where the configuration of the connector parts have prominent surfaces or projections that interfere with the coupling advance of mating end connectors.[0003]Typically, main runners are 12′ long and are installed by a technician who, during an installation,...

AI Technical Summary

Benefits of technology

[0006]The invention provides a main tee splice connector of the type disclosed in U.S. Pat. No. 6,729,100 that affords a significant increase in tensile capacity. This increase in strength where the end connector is integral with the main part of the grid runner or tee enables the grid runner to perform at a higher rating or service duty than previously obtained. Conversely, with the integral splice of the present invention, previous service ratings can be obtained with lighter gauge material than has previously been used in the manufacture of main grid runners.

[0007]As disclosed, the basic configuration of the inventive splice connector is the same or similar to the prior art connector of U.S. Pat. No. 6,729,100. Consequently, the self-aligning and consistent performance attributes of the former design are retained. Additionally, the inventive new connector is compatible with the early connector thereby reducing or eliminating inventory and changeover problems. Additionally, the presently disclosed new connector affords a potential improvement in alignment between abutted main runners by virtue of an increased spacing of connector lock elements that can resist and / or reduce non-parallelism on a vertical plane at the splice joint.

[0008]In the illustrated embodiment, the end tab has elements for aligning itself to the receiving pocket of an opposed connector in both the vertical and horizontal directions. The vertical alignment feature is advantageously effective from a condition where the end tab misalignment is physically limited by the flange of the opposed tee runner. This structure enables a connection to be made where the end tab is first laid on the flange of the opposing previously installed runner and then is simply subjected to an endwise force by the installer. The leading profile of the end tab is effective, in the vertical location established by the flange of the opposed tee, to cam the end tab towards alignment with the mating connector. The vertical self-aligning character of the end tab is augmented by a lock lance element that registers with a groove in an opposed connector end tab. The vertical alignment action of the lock lance is assisted by horizontal alignment elements of the connector. The horizontal alignment elements of the connector comprise a lead angle formed by bending the forward portion of the end tab out of the plane of a main portion of the end tab and an outwardly flared entrance to the end tab receiving pocket. These lead angle and flared entrance elements provide relatively large, smooth caroming surfaces, as compared to edge areas, that improve the smooth functioning of the connector. The lead angle of the end tab and outward flare of the opposed connector are readily inter-engaged for horizontal alignment. Additionally, these lead angle and outward flare components avoid any direct edge-to-surface contact between these components so that smooth sliding action occurs when the lock lance moves out of the relief groove of the opposed connector in the late stages of the assembly movement where the potential interference between the connectors is greatest.

Problems solved by technology

Various known end connectors for main runners or tees can be somewhat difficult to install for numerous reasons.

Such connectors may not be self-aligning and if they have provisions for self-alignment, their performance in this regard may be marginal at best.

Smooth engagement and coupling between end connectors can be obstructed where the configuration of the connector parts have prominent surfaces or projections that interfere with the coupling advance of mating end connectors.

Thus, the technician is at least 6′ away from the joint so that it is difficult for the technician to clearly see the end receiving pocket of the preceding runner.

Moreover, from this location, the technician cannot cup the ends to be joined in one hand to align them together.

A more subtle but sometimes more troublesome problem occurs when the end connectors are out or nearly out of dimensional tolerance due to variations in material stock, tool wear or other manufacturing conditions.

In this circumstance, the forces required to connect the ends of the runners may vary from one runner to the next so that the technician installing the grid is confounded by not knowing for sure if a good connection is being made.

Additionally, these dimensionally marginal parts can require excessive assembly force, again to the distraction or frustration of the technician.

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